IP0504 MACHINE TOOL DESIGN

Prerequisites (if any):

Objectives: 1. To make the students understand the concepts & broad principles of contents of the
course
2. Develop conceptual framework of the course
3. Aim is to provide insight of the subject
4. Sensitizes the students of the importance of course in real life environment

Unit1:Design of Machine Tool Drives

1) Selection of Electric Motor
2)Stepped Regulation of Speed, Laws of Stepped Regulation, Why Geometric Progreession is used
against Arithmetic, Harmonic & Logarithmic despite shortcomings, Relation between Range ratio,
Geometric Progression Ratio and No. of Speed Steps
3)Design of Stepped Drives:
Break up of Speed Steps, Structural Formulae, Structural Diagram, Selection of Best Structural
Diagram, Ray Diagram, Speed Chart, General recommendations for Developing the Gearing Diagram,
Determining the number of teeth of Gears
a) Speed Gear box : Limiting Transmission Ratio of Speed Gear Box,
Design Case Study of Speed Gear Box for Lathe,
Classification of Speed Gear Boxes
b) Feed Gear box: Limiting Transmission Ratio of Feed Gear Box,
Design Case Study of Feed Gear Box (with Gear Cone & Sliding Key) for Drilling Machine,
Classification of Feed Gear Boxes, Study of Application of Norton’s & Meander’s Mechanism for
Thread Cutting
4) Step less Drives
Step less Regulation of Speed & Feed Rates through Hydraulic, Electric & Mechanical means,
Positively Infinitely Variable Drive, Case Study of CNC Lathe with Electronic Controller for Speed &
Feed Step less Regulation

Unit 2:Design of Machine Tool Structure

Function & Requirement of Machine Tool Structure, Design Criteria from Strength & Stiffness
considerations, Concept of Unit Rigidity, Unit Strength under Tension, Unit Strength under Torsion &
Unit Strength under Bending for Material of Machine Tool Structures, Compare Steel & Cast Iron on
the basis of Material Properties, Manufacturing Problems and Economy, Role of Static & Dynamic
Stiffness in the design of elements of machine tools, Profiles of Machine Tool Structures, Factors
affecting stiffness of machine tool structures & methods of improving it, Basic Design procedure of
machine tool structures. Design Case Studies of a)Bed of Lathe, b)Column & Base of Milling Machine,
c)Housing of Speed Gear box

Unit3: Design of Guideways

Function & Types of Guideways, Types of Slideways & Antifriction Ways,

Functional features of Slideways, its Shapes & Materials, Methods of adjusting Clearance, Design
Criteria (Wear Resistance & Stiffness) and Calculations for Slideways operating under semi liquid
friction condition, ‘Stick Slip’ phenomena affects accuracy of setting & working motions.
Comparison of Design & stiffness of Hydrodynamic, Hydrostatic & Aerostatic Slideways,

Design of Antifriction Guideway, Concept of Combination Guideways

Unit 4:Design of Power Screws

Design of Sliding friction Power Screw for Wear Resistance, Strength, Stiffness, & Buckling Stability.

Design of Rolling friction Power Screw for Strength under static loading, Strength under cyclic loading,
& Stiffness

Unit 5: Design of Spindle

Function & Requirements of Spindle Units, their Materials,

Effect of Machine Tool Compliance on Machining accuracy
Design of Spindle for Bending Stiffness : Deflection of Spindle Axis due to a)Bending, b) - due to
Compliance of Spindle Supports, c) - due to Compliance of the Tapered Joint

Optimum Spacing between Spindle Supports

Permissible Deflection & Design for stiffness: Additional Check for Strength like Additional Supports,
Location of Bearings and Drive elements, Balancing

Unit 6: Design of Spindle Supports

Requirements of Spindle Supports
Features of Anti-friction Bearings,Load bearing abilities of Ball & Roller Bearings. Parameters which
asses the viability of combination of roller & Ball & Roller Bearings in Spindle Units. Preloading of
Anti Friction Bearing & its method

Design of Sliding Bearings: Sleeve, Hydrodynamic Journal, Hydrostatic Journal,

Air-Lubricated (Aerodynamic, Aerostatic)
Time: 7hrs per unit
Outcomes: At the end of the course student will be in a position to
1. List down the factors that influence the application of the course content in the industrial
environment
2. Undertake final year project work based upon the application of the course content
3. Identify areas for research oriented work based on the course content
4. Apply the knowledge of the course in solving real life problems

Text Books:
1. N. K. Mehta, “Machine Tool Design”, Tata McGraw Hill, ISBN 0-07-451775-9.
2. D. K Pal, S. K. Basu, “Design of Machine Tool”, 4th Edition. Oxford IBH 2005, ISBN
81-204-0968
Reference Books

1. Bhattacharya and S. G. Sen., “Principles of Machine Tool”, New central book agency Calcutta,
ISBN 81-7381-1555.
2. N. S. Acherkan, “Machine Tool”, Vol. I, II, III and IV, MIR publications.
3. F. Koenigsberger, “Design Principles of Metal Cutting Machine Tools”, The Macmillan
Company New York 1964.
 IP0184 OPERATIONS RESEARCH

Prerequisites (if any):

Objectives:
 To make the students understand the concepts & broad principles of contents of the course
 Develop conceptual framework of the course
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

UNIT 1 INTRODUCTION & FORMULATION OF LPP MODEL

OR methodology, Definition of OR, Application of OR to engineering and Managerial problems,

Features of OR models, Limitation of OR, formulation LPP Models.

UNIT 2 :-LINEAR PROGRAMMING

Definition, mathematical formulation, standard form, solution space, solution – feasible, basic feasible,
optimal, infeasible, multiple, optimal, Redundancy, Degeneracy. Graphical and simplex methods.
Variants of simplex algorithm – Artificial basis techniques, Big M Method

UNIT 3: TRANSPORTATION & ASSIGNMENT PROBLEM

Formulation of transportation model, Basic feasible solution using different methods (North-West
corner, Least Cost, Vogel’s Approximation Method) Optimality Methods, Unbalanced transportation
problem, Degeneracy in transportation problems, Variants in Transportation Problems, Applications of
Transportation problems. Transhipment problems. Formulation of the Assignment problem, unbalanced
assignment problem, travelling salesman problem

UNIT 4:CPM & PERT

Network construction, determination of critical path and duration, floats. PERT- Estimation of project
duration, variance.

UNIT 5 :-REPLACEMENT ANALYSIS

Replacement of capital equipments that deteriorates with time,
time value of money (a) remains same (b) changes with constant rates during period.
Equipment renewal policy, group and individual replacement.
Individual Replacement, Group Replacement Policies, Problems.

Unit 6: games theory

Introduction, two -person zero sum game, minimax and maximin principle, saddle point, methods for
solving game problems with mixed strategies, Graphical and iterative methods, solving game by LP
Method.
Outcomes: At the end of the course student will be in a position to
 List down the factors that influence the application of the course content in the industrial
environment
 Undertake final year project work based upon the application of the course content
 Identify areas for research-oriented work based on the course content
  Apply the knowledge of the course in solving real life problems

TEXT BOOKS:
1. Taha H A Operation Research and Introduction, McMillian.ISBN-0-02-418940-5
2. Paneerselvam Operations Research , Prentice Hall of India

REFERENCE BOOKS:
1. Hiller and Libermann, Introduction to Operation Research, McGraw Hill 5th edn.
2. S.D. Sharma – Operations Research, Kedarnath, Ramnath &Co
3. J K Sharma, Operations Research Theory and Application, Pearson Education Pvt Ltd ,2nd Edn,
ISBN-0333-92394-4
4. Kanthi Swarup & others – Operations Research, Sultan chand and Sons.
5. Philips, Ravindram and Soleberg-Principles of Operations Research – Theory and Practice, PHI
 IP0514 FINITE ELEMENT METHOD AND COMPUTER AIDED DESIGN

Prerequisites (if any):

Objectives:
1. To make the students understand the concepts & broad principles of contents of the course
5. Develop conceptual framework of the course
6. Aim is to provide insight of the subject
7. Sensitizes the students of the importance of course in real life environment

UNIT1.CAD / CAM HARDWARE / SOFTWARE

Types of Computer systems - Input devices - Output devices - CAD/CAM Software - Graphics
standards – Basic Definitions Modes of Graphics Operations -User Interface - Software modules-
Modelling and Viewing - Software Development - Efficient use of CAD/CAM Software -
Microcomputer based CAD/CAM.

UNIT2. TWO DIMENSIONAL AND THREE DIMENSIONAL TRANSFROMATIONS

2D - Representation and Transformation of Points - Transformation of Lines -Rotation, Reflection,
Scaling and combined transformations - 3Dscaling - shearing - Rotation - Reflection - Translation -
Projections parametric representation of Ellipse, Parabola, Hyperbola.

UNIT 3. PART MODELLING and ASSEMBLY

Introduction to Wire frame, Surface and Solid modeling, Part Modeling : Introduction, Sketch, Base
features, datum features, sections in sketch based features, Edit feature, Engineering features,
Construction features, Advanced features, Tweak feature, UDFs & Group, Relation & family Table,
Resolving feature failures
Assembly : Creating Assemblies, placing, patterning, packaging, freeform Manipulation of
components, Top Down Assemblies, Exploded view.
Detail : Drafting basics, creating a Drawing with Model views, Dimensioning & Detailing, Tables &
BOM Balloons

UNIT 4. SHEET METAL: Sheet metal: Introduction creates conversion, wall, rip, cut, form, flatten
form, notch punch, and bend, unbend, bend back, corner relief, deform, edge bend.

UNIT 5. FINITE ELEMENT ANALYSIS (FEA): Introduction to Finite element modeling,

coordinate and shape function, Potential energy approach, assembly of global stiffness matrix and load
vector, properties of stiffness matrix, finite element equations, Finite element equations: treatment of
boundary conditions, types of boundary conditions, elimination approach, penalty approach, quadratic
shape function for 1-D element, introduction to plane trusses, local and global coordinate systems,
element stiffness matrix, stress calculations

UNIT 6. 2-D FINITE ELEMENT ANALYSIS: Constant strain triangle, isoparametric representation,
potential energy approach, element stiffness, force terms, stress calculations
Time: 7hrs per unit

Outcomes: At the end of the course student will be in a position to

2. List down the factors that influence the application of the course content in the industrial
environment
3. Undertake final year project work based upon the application of the course content
4. Identify areas for research oriented work based on the course content
5. Apply the knowledge of the course in solving real life problems

Text Books
1. Ibrahim Zeid, CAD/CAM, " Theory and Practaice ", Tata McGraw-Hill Ed., 1998.
2. David F.Rogers and Alan Adams.J, " Mathematical Elements for Computer Graphics",
McGraw-Hill Publishing Company International Edition, 1990.

Reference Books
1. William M.Newman, Robert F.Sproull, " Principles of Interactive Computer Graphics",
2. McGraw-Hill International Book Company, 1984.
3. Groover M.P., Automation, " Production Systems and Computer Integrated Manufacturing ",
4. Prentice-Hall of India Pvt.Ltd., New Delhi, 1996.
 IP5504 MACHINE TOOL DESIGN LAB
Prerequisites (if any):

Objectives:
• To develop skills in the subject
• Verify the principles of the course
• Application of the theory
Understanding of fundamentals of the subject

List of practicals
1. Design and working drawing of Speed Gear Box
2. Design and working drawing of Feed Gear Box
3. Study of Step-less Drives
4. Design of Base
5 Design of Bed
6 Design of Column
7 Design of Slide ways
8 Design of Spindle &
9 Design of Spindle-Support
10 Power Screw Design (Sliding & Rolling friction)
11 Design of Guide ways
12 Study of Machine Tool Control Systems
Outcomes: The student will

• have improved hands on skills

• be in a position to relate theory and practice
• Develop the practical aspects of the theory knowledge
• be in a position to explain the procedure of the experiments

Text Books:
1. N. K. Mehta, “Machine Tool Design”, Tata McGraw Hill, ISBN 0-07-451775-9.
2. D. K Pal, S. K. Basu, “Design of Machine Tool”, 4th Edition. Oxford IBH 2005, ISBN
81-204-0968

Reference Books

4. Bhattacharya and S. G. Sen., “Principles of Machine Tool”, New central book agency Calcutta,
ISBN 81-7381-1555.
5. N. S. Acherkan, “Machine Tool”, Vol. I, II, III and IV, MIR publications.
6. F. Koenigsberger, “Design Principles of Metal Cutting Machine Tools”, The Macmillan
Company New York 1964.
 IP5184 OPERATIONS RESEARCH LAB

Prerequisites (if any):

Objectives:
 To develop skills in the subject
 Verify the principles of the course
 Understanding of fundamentals of the subject

LIST OF PRACTICAL

1) Assignment on formation of LPP Model

2) Assignment on Graphical methods.
3) Assignment on simplex methods
4) Assignment on Big M Method & Dual simplex method
5) Assignment on TRANSPORTATION PROBLEM
6) Assignment on ASSIGNMENT PROBLEM
7) Assignment on Network Construction.
8) Assignment on CPM & PERT
9) Assignment on Individual Replacement
10) Assignment on Group Replacement
11) Assignment on game problems with mixed strategies,
12) Assignment on solving game problems by Graphical methods & LP Method.

Outcomes: The student will

 acquire the skills
 improve ability to solve industrial problems on the subject
 be in a position to relate theory and practice
 Develop the practical aspects of the theory knowledge
 be in a position to explain the procedure of the experiments

TEXT BOOKS:
1. Taha H A Operation Research and Introduction, McMillian.ISBN-0-02-418940-5
2. Paneerselvam Operations Research , Prentice Hall of India
3. Philips, Ravindram and Soleberg-Principles of Operations Research – Theory and Practice, PHI

REFERENCE BOOKS:
1. Hiller and Libermann, Introduction to Operation Research, McGraw Hill 5th edn.
2. S.D. Sharma – Operations Research, Kedarnath, Ramnath &Co
3. J K Sharma, Operations Research Theory and Application, Pearson Education Pvt Ltd ,2nd Edn,
ISBN-0333-92394-4
4. Kanthi Swarup & others – Operations Research, Sultan chand and Sons.
 IP5514 FINITE ELEMENT METHOD AND COMPUTER AIDED DESIGN LAB
Prerequisites (if any):

Objectives:
1. To develop skills in the subject
2. Verify the principles of the course

1. Creating sketches:- Drawing and dimensioning a line, rectangle, circle and arc, modifying
dimensions, creating fillets
2. Basic solid modeling:- Creating holes, rounds and chamfers, use of patterns and copying features
3. Advanced modeling tools:- Sweep features, blend features
4. Assembly modeling:- Creating top-down and bottom-up assemblies, assembling the components
5. Detailing of the drawing views:- Generating the drawing views and dimensioning the views
6. Sheet metal modeling:
7. Finite element analysis of 2-D truss:
8. Finite element analysis of simple machine component:

Outcomes: The student will

1. Acquire the skills
2. Have improved hands on skills
3. Be in a position to relate theory and practice
4. Develop the practical aspects of the theory knowledge

Text Books
1. Ibrahim Zeid, CAD/CAM, " Theory and Practaice ", Tata McGraw-Hill Ed., 1998.
2. David F.Rogers and Alan Adams.J, " Mathematical Elements for Computer Graphics",
McGraw-Hill Publishing Company International Edition, 1990.

Reference Books
5. 3. William M.Newman, Robert F.Sproull, " Principles of Interactive Computer Graphics",
6. McGraw-Hill International Book Company, 1984.
7. Groover M.P., Automation, " Production Systems and Computer Integrated Manufacturing ",
8. Prentice-Hall of India Pvt.Ltd., New Delhi, 1996.
 IP5524 PROJECT –I

Objectives
 To undertake small project in group related to application of principles studied during the
course
Prerequisites

The student shall take up suitable project, the scope of the project shall be such as to complete it with the
time schedule, The term work shall consist of,
1. Fabrication of models, machines, prototypes based on new ideas, robots and machine based on hitech
systems and automation, experimental set-up, fabrication of testing equipment, renovation of machines,
etc. Above work shall be taken up individually or in groups. The group shall not be more than 4
students,
OR
Extensive analysis of some problems done with the help of a computer individually or in a group not
exceeding two students.
2. A detailed report on the work done shall include project specification, design procedure, drawings,
process sheets, assembly procedure and test results etc.

Project may be of the following types:

1. Manufacturing / Fabrication of a prototype machine' including selection, concept, design, material,
manufacturing the components, assembly of components, testing and performance evaluation.
2. Improvement of existing machine / equipment / process.
3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment, inspection gauges,
measuring instruments for machine tools.
4. Computer aided design, analysis of components such as stress analysis.
5. Problems related to Productivity improvements.
6. Problems related to value engineering.
7. Problems relating to material handling system.
8. Energy Audit of organization, Industrial evaluation of machine devices.
9. Design of a test rig for performance evaluation of machine devices.
10. Product design and development.
11. Analysis, evaluation and experimental verification of any engineering problem encountered.
12. Quality systems and management. Total Quality Management.
13. Quality improvements, In-process Inspection, Online gauging.
14. Low cost automation, Computer Aided Automation in Manufacturing.
15. Time and Motion study, Job evaluation.
16. Ergonomics and safety aspects under industrial environment
17. Management Information System.
18. Market Analysis in conjunction with Production Planning and Control.
OR
Computer based design / analysis or modeling / simulation of product(s), mechanism(s) or system (s)
and its validation or comparison with available benchmarks / results. When a group of students is doing
a project, names of all the students shall be included on every certified report copy. Two copies of
Project Report shall be submitted to the college. The students shall present their Project before the
examiners. The oral examination, shall be based on the term work submitted and jointly conducted by an
internal and an; external examiner from industry, at the end of second semester. Format of the project
report should be as follows:
1. Paper: The Project report should be types. printed on white paper of A-4 size.
2. Typing: The typing shall be with single spacing and on one side of the paper.
3. Binding: The Industrial Inplant Report should be submitted with front and back cover in black hand
bound, with golden embossing.
4. Margins: Left - 1.25", Right - 1". Top and Bottom 1 "
5. Sequence of Pages:
1. Title page
2. Certificate form Institute
3. Completion Certificate form Industry, if sponsored.
4. Acknowledgement
5. Abstract
6. Index
7. Nomenclature and Symbols
8. Actual Content
9. Conclusion
10. References.
6. Front cover: The front cover shall have the following details in block capitals
i. Title at the top.
ii. Name of the candidate in the centre, and
iii. Name of the Institute, Name of Industry, if sponsored and the year of submission on separate lines, at
the bottom.
7. Blank sheets: No blank sheets be left any where in the report. 8. Project Completion Certificate:
The approval sheet follow the title sheet and shall be as shown with proper spacing.

CERTIFICATE
This is to certify that Mr. /Ms
…………………………………………………
Has carried out a Project entitled, (Name)

…………………………………………during the course of his

(Name of Project)
training at………………………………………………..in
(Name of Industry)
partial fulfillment of the requirement of the B.E. Production Course of
University of Pune
at ……………………………during the academic Year ………………
(Name of Industry)

Date: (Guide)
Place:

(Examiner) (Head of Department)

 IP0224 RELIABILITY ENGINEERING

Prerequisites (if any):

Objectives:
 To make the students understand the concepts & broad principles of contents of the course
 Develop conceptual framework of the course
 Aim is to provide insight of the subject

Unit I
Introduction to Reliability
Importance of reliability, performance cost and reliability, quality and safety, system configuration with
examples, stochastic processes, bathtub concept, MTBF, MTTR, hazard rate, failure rate, probability
and sampling, cumulative probability distribution function, data and distributions.
Unit II
System safety analysis
Fault tree and event tree concept, construction and analysis, failure modes effects and criticality
analysis, systems approach, techno-physio constraints, typical failure analysis, risk priority number and
its allocation.
Unit III
Reliability in design and Life Cycle costing
Survival rate, bath-tub curve analysis of characteristics of failure regimes, design synthesis, reliability
effort function, safety margin, allocation of reliabilities by AGREE, ARINC, proportional distribution of
unreliability, heuristic method, mean and median methods.
Unit IV
System reliability and redundancy
Active and Passive Redundancy, redundancy allocation and limitations, Evaluation of overall system
reliability, Conditional probability, Matrix methods, set theory analysis of system reliability.
Unit V
Loads, capacity, maintainability and availability
Reliability and safety factors, Repetitive loading, Preventive maintenance, Testing and repair, reliability
centered maintenance, system availability and maintainability.
Unit VI
Reliability testing and Failure Interactions
Reliability growth models, grouped. and ungrouped data, censored data, accelerated life testing, Markov
analysis .of two independent components, reliability with standby system, multicomponent systems,
DTMC and CTMS models.

Time: 7hrs per unit

Outcomes: At the end of the course student will be in a position to
 Undertake final year project work based upon the application of the course content
 Identify areas for research-oriented work based on the course content
 Apply the knowledge of the course in solving real life problems

Text Books:
1. E. E. Lewis, “Introduction to Reliability Engineering”, John Wiley and Sons.
2. L. S. Srinath, “Reliability Engineering”, Affiliated East-West Press Pvt. Ltd., ISBN 81-
85336-39-3.
References Books:
1. S. K. Basu, B. Bhadury, “Terotechnology-Reliability Engineering and maintenance”, Asian
books Pvt. Ltd (2003), ISBN 81-86299-40-6.
2. Sheldon M. Ross, “Stochastic Processes”, John Wiley and Sons.
3. S. S. Rao, “Reliability Engineering”.
 IP0264 PRODUCTION AND OPERATIONS MANAGEMENT

Prerequisites (if any):

Objectives:
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

Course Contents:
1. Introduction: History of Operations Management, Operations Organization. Concept of
manufacturing and operations management engineering productivity, efficiency utilization,
difference between products and service, interrelationship of profitability and productivity,
productivity in relationship to material
2. Operations Strategy: Competitiveness with Operations, Competing on cost, quality, flexibility,
speed, Productivity, efficiency & effectiveness.
3. Products & Services Design: New product development: strategies and processes, design process,
Cross functional product design, designing for manufacture and assembly, designing for customer,
concurrent design and concurrent engineering, considerations in service design, Product design tools
– QFD, Value analysis, Modular design, Product life cycle, Taguchi methods, Process analysis,
process flow charting, types and evaluation,
4. Processes & Technology: Types of production systems – Mass, Process, Job Shop, Batch, Project,
etc. Process selection types, flow structures, process re-engineering, product process matrix and
virtual factory, Technology decisions, Classification of process technologies - manual, mechanized
& automated, Process technology in service and non manufacturing operations - distribution and
transport, warehousing, point of sale system and banking operations.
5. Facilities Layout: facility location analysis, basic layouts, designing process layouts, designing
product layouts, designing hybrid layouts, Locating production and services facilities: importance of
location factor affecting location decisions, Introduction to the concept of line balancing, cycle time,
determination of workstation and efficiency, sensitivity analysis of the same.

6. Material Handling Systems: as a necessary evil, indicators of poor material handling, principle of
good material handling system, different material handling equipment, Material handling function,
MH principles, MH Equipment – Cranes & Hoists, Conveyors, Industrial Trucks, AGVs, AS-RS
systems, etc.

Time: 7 hrs per unit

Outcomes: At the end of the course student will be in a position to
 List down the factors that influence the application of the course content in the industrial
environment
 Undertake final year project work based upon the application of the course content
Text book:
1. Operations Management for Competitive Advantage: Chase, Aquilano and Jacobs, TMH

Reference books:
1. Production and Operations Management by Gaither Norman & Frazier,1999- Southwestern
2. -Purchase Management : By L.C. Jhamb-2000-Everest publication
3. -Production and Operation Management : By S.N Chary-1988- Tata Mc Graw Hill
 4. -Production and Operation Management by Adams, Evereet & Ronald J, 1996, 5/e, PHI

IP0204 PLANT ENGINEERING

Prerequisites (if any):

Objectives:
 Develop conceptual framework of the course
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

UNIT1:Introduction:

Concept Of Plant Facility, It’s Scope, Importance And Objectives. Plant Facility Location: Nature
Of Location Decision, Need For Facility Location Planning, General Procedures And Factors
Influencing Location Decisions, Facility Location Models, Economics And Cost Analysis, Rural
And Urban Location Pattern In India.

UNIT2:Layout Designs:

Industrial Plant Design Considerations, Types Of Production Types Of Layout, Factors Affecting
Layout Tools, Techniques & Procedure Used In Workstation And Plant Layout, Quantitative
Techniques In Plant Layout, Developing Product And Process Layouts, Comparing Layouts,
Criteria For Computerized Facility Layout, Concept Of Computerized Layout Programs Like
Craft, Corelap, Aldep & Planet.

UNIT3: Flow Patterns Designs:

Overall System Flow Cycle, Need And Advantages Of Planned Material Flow, Factors For
Consideration, Designing Flow Patterns, Flow Patterns For Production Lines And Assembly Lines.

UNIT4:Group Technology And Flexible Manufacturing Systems- Concepts: Fundamentals,

Group Technology Approaches, Characteristics Of A Group/ Cell Families Of Parts, Coding
Systems, Production Flow Analysis And Choice Of Family , Benefits And Applications Of Group
Technology, Concept Of Flexible Manufacturing System.

UNIT5:Material Handling:

Scope And Functions Of Material Handling , Manual Mechanical Handling Ratio, Principles Of
Material Handling , Analysis Of Material Handling Problem, Classification Of Material Handling
System, Salient Features And Applications Of General Purpose Material Handling Equipments ,
Material Handling In Stores And Warehouses , Automation In Part Handling ,Handling And
Industrial Robots, Optimum Allocation Of Material Handling Equipment.

UNIT6: Plant Maintenance:

Role Of Maintenance Management , Organization & Systems Of Maintenance Management ,

Different Types Of Maintenance Management , Their Purpose And Features, Preventive And
 Predictive Maintenance Techniques, Introduction To Total Productive Maintenance: Concepts,
Tools And Procedure.

Time: 7 hrs per unit

Outcomes: At the end of the course student will be in a position to
 Identify areas for research oriented work based on the course content
 Apply the knowledge of the course in solving real life problems

Text Books
1. Practical Plant layout By Multher
2. Plant layout and design By James More

Reference Books
1. Manufacturing management a Quantitative Approach By Robert A Olsem
2. Productions & Operations Management By Lockyer Mulleman & Oakland
3. Operations and Industrial Management By Del mar
4. Plant Layout and Material Handling ..By James M Apple
5. Plant Layout By Immer
6. Plant Layout By Shubin
7. Material handling By Allexander
8. Material Handling Equipment By N Rudenko
9. Engineering Economy ( 7th edition ) By Degarmo Sullivan & Canada.
10. Industrial Engineering and O.R. By Miller & Schmidt.
 IP0054 PROJECT MANAGEMENT

Prerequisites (if any):

Objectives:
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

Unit 1
Introduction: Defination of project, difference with respect to standard routine production. Parameters
involved in Project identification. Difference in projects under private, public & joint sector.

Unit 2
Types of project: projects under BMRED – Balancing, Modernization, Replacement, Expansion &
Diversification; Consideration involved in decision-making in each of these.

Unit 3
Project Formulation: Preparation of feasibility Report & Specification; Budgeting; criteria for pre-
investment decision; Incentives from state & central govt.; Import-substitution projects.

Unit 4
Project Finance; source of Finance for project; Local & Foreign investments.
Project Appraisal-i)Techno-commercial, ii) Financial- Discounted cash flow, rate of return, iii)Non
financial benefit, iv) Socio-economic cost benefit analysis.

Unit 5
Project costing: Costs of Contracting; Labour & Equipment costs; Development & Codification of cost
data; Accounting; Activity-Based costing.

Unit 6
Project Administration: Cash flow planning; Project scheduling; PERT, CPM &GANTT Charts; Time-
Cost trade –off; Project overruns costs; Participation & Team work.

Time: 7 hrs per unit

Outcomes: At the end of the course student will be in a position to
 Identify areas for research oriented work based on the course content
 Apply the knowledge of the course in solving real life problems

Text Books

1. Narendra Singh; Project Management & Control (1998 ); Himalaya Publishing House,
Mumbai.
Reference Books
1) Gopal & Ramamurthy; Project Management Handbook; Macmilan.
2) Prasanna Chandra; Preparation, Appraisal, Budgeting&Implementation
3) S.Choudary, Project Management
 IP0594 POWDER METALLURGY
Prerequisites (if any):

Objectives:
 To make the students understand the concepts & broad principles of contents of the course
 Develop conceptual framework of the course

Unit I
Powder Metallurgy (7)
Historical development, Introduction, Basic principles, techniques, classification,. Production of metal
powders: reduction, atomization, and electrolysis etc. Characteristics of powders and properties,
production methodology and quality control. Preparation of powder: grading, sizing, blending, handling
and storage. Testing of powders. Particle size distribution, surface conditions, purity, flow properties,
porosity, true and apparent density, Green compact strength.

Unit II
Compaction (7)
Fundamentals of compaction, presses used, selection of presses, Automation and Handling of powder,
tool clearances, Die design principles, wear reclamation, Die and punch materials selection and heat
treatment, surface treatment properties, compact density variations, effect of blending powders,
lubricants and lubrication in process.

Unit III
Sintering (7)
Principle, time temperature effects, theories of sintering mechanism. Sintering methods, sintering
furnaces-characteristics and selection. Dimensional and property changes after sintering, sintering
atmosphere and its impact on process performance. Hot compaction, hot and cold pressing, spot
sintering operations, impregnation.

Unit IV
Special P.M. processes (7)
Hot isostatic pressing, merits, demerits and typical applications. Powder Metal products with polymer
blends, expendable and retaining roll compaction. P.M. forging, Spray, deposition and surface structure
development.

Unit V
Powder Metallurgy Applications (7)
As structural parts, gears, levers, ratchets, etc. lamp filament and filament support, refractory metal
components, electrical contact material, Cemented Carbide tools and wear parts, brakes and clutch lining
material, porous bearings and filters, catalytic components etc.

Unit VI
Powder Metallurgy Components characteristics (7)
Economics, Quality, Manufacturing Competitiveness due to conservation of energy, Materials,
Operations, Durability, rigidity, near net – shape, surface finish and machining.
Heat treatment of Powder Metallurgy parts, Advantages and limitations of powder metallurgy, typical
applications.
Quality control and quality assurance. Newer materials, production of nano-composites.

Time: 7 hrs per unit

Outcomes: At the end of the course student will be in a position to
 Students will understand basic techniques of Powder Metallurgy
 Undertake final year project work based upon the application of the course content

Text Books:
1. A.K Sinha, “A textbook of power Metallurgy”, D.P. Tai.
2. F. Thummler and R. Oberacker, An Introduction to Powder Metallurgy, The Institute of
Materials, London
3. W.D Jone, “Fundametal principals of power Metallurgy”, Edword Arnold (UK)

Reference Books:
1. A practical Guide to Metal Powder”, Hogans India Ltd.
2. Yarten, Argly, “Power Metallurgy”, Machinery Publishing U.K.
3. Hari Singh Nalwa (Editor), “Handbook of Nano-structured Materials and Nanotechnology”Vol
1-5, Springer Verlang
4. Powder Metallurgy ASM Handbook Vol.VII
 IP0554 MANUFACTURING AUTOMATION AND CAM
Prerequisites (if any):

Objectives: 1. To make the students understand the concepts & broad principles of contents of the
course
8. Develop conceptual framework of the course
9. Aim is to provide insight of the subject
10. Sensitizes the students of the importance of course in real life environment

UNIT 1. Automation ,hydraulics and pneumatics

Automated manufacturing systems,levels of automationautomation principles and strategies,principles
of hydraulics and pneumatics,basic hydraulic circuits,hydraulic servo mechanism,proportional
valves,design of pneumatic circuits,hydroneumatic and electropneumatics,control in pneumatic systems.

UNIT 2.Hard and soft automation

SPMs, automats,Transfer lines,types,work part transfer mechanisms,control of production line,transfer
line performance,CNC machines,machining centers.

UNIT 3. Programmable automation.

Microprocessor,microprocessor instrumentation system for process control,logic gate and
control,PLC,computer process control,control system components,ADC/DAC conversion,linear
feedback control system,PID control

UNIT 4. Automatic material handling and inspection

.Automated guided vehicles systems,conveyor systems,analysis,carousel storage systems,automated
inspection,automatic gauging system

UNIT 5. Factory automation

Assembly systems,automated assembly,design for automated assembly,synchronous and non
synchronous material transfer,vibratory bowl feeders,hopper feeders,rotary disc
feeders,centrifugal,revolving feeders,industrial robots.

UNIT 6. Computer aided manufacturing,CIM and FMS.

DNC,cellular manufacturing,group technology,flexible manufacturing systems,computer control
systemFMS planning and implementation,Elements of CIM system

Outcomes: At the end of the course student will be in a position to

6. List down the factors that influence the application of the course content in the industrial
environment
7. Undertake final year project work based upon the application of the course content
8. Identify areas for research oriented work based on the course content
9. Apply the knowledge of the course in solving real life problems

TEXT BOOKS:
1.Automation,Production Systems and Computer Integrated Manufacturing-Mikell P Groover ,Pearson
Education Asia,2001
2.Pneumatic System-S.R.Majumdar,Tata McGraw Hill 2002 edition
REFERENCE BOOKS:
1.Mechanisation by pneumatic control-Werner Deport and Kurt Stool,Vol.1,2
2.Control Systems Engineering-Gopal,Willey Eastern Ltd
3.Hydraulics and Pneumatics –Andrew Parr
4.Microprocessor-Gaonkar,Penram International
 IP0544 PROCESS ENGINEERING

Teaching scheme:
Lectures: 3 hours per week

Pre requisites : Knowledge about basic machining processes and tooling.

Course Objective
To develop the Process planning skill for the manufacturing .

Unit 1

Product and Process Engineering

General Manufacturing processes, Product Engineering, DFM, DFMA ,Process Engineering,
communications,
Part Print analysis-Establishing general characteristics of work piece, Auxiliary methods for
visualizing part print, Functional surfaces, nature of work piece, finishing and identifying operations,
relating the part to assembly.

Unit 2
Dimensional and tolerance analysis
Types of dimensions, Measuring geometry of form –Flatness, parallelism, straightness,
squareness, angularity ,roundness, concentricity and eccentricity ,symmetry surface quality and surface
integrity, surface finish affecting product properties and product cost, base lines, direction of specific
dimensions .
Tolerance analysis-causes of work piece variations, to express limits and tolerance, tolerance stack,
purpose of tolerance chart, Rules for adding and subtracting ,layout of tolerance chart.

Unit 3
Work piece Control &Classifying operations
Equilibrium theories, concept of location, geometrical control, dimensional control, mechanical
control. alternate location.
Classifying operations : Basic process operations, principal process operations, major operations,
qualifying and requialifying operations, auxiliary process operations.

Unit 4
Selection of Equipment and toolings
Process selection and machine selection, sources for selection , General purpose ,special
purpose machines, factors in machine selection in terms of cost and design factors, cost analysis,
operating cost, comparative cost analysis
Classification of tooling : sources of tooling, tool holders, work piece holders, jigs fixtures
moulds, pattern, core boxes, dies, templates, gauges,

Unit 5
Selecting and planning the process
 Function, Economy and appearance, fundamental rules for manufacturing process,
Engineering approach, basic design of product, influence of process engineering on product design,
specifications ,materials and its cost analysis, eliminating operations, combined operations, selecting
proper tooling, availability of equipment, effect of operations speed on performance of economy, make
or buy decision. Computer aided process planning.

Unit 6
Process sheet design
Determining manufacturing sequence, Factors for operation sequence, major process
sequence, combining operations, Operation routing, routing uses routing description, process picture,
process picture sheet, processing dimensions and views.

Outcomes: At the end of the course student will be in a position to

10. List down the factors that influence the application of the course content in the industrial
environment
11. Undertake final year project work based upon the application of the course content
12. Identify areas for research oriented work based on the course content
13. Apply the knowledge of the course in solving real life problems

TEXT BOOKS:

1. D.F.Eary, G.E.Johnson” process engineering for manufacturing”; Prentice-Hall

2. P.W.Wang, J.Kelly” computer aided process planning
3. Nanua singh, “System approach to computer integrated design and manufacturing”

REFERENCE BOOKS:

1. H.W.Wage, “Manufacturing Engineering”, McGraw hill

2. “Manufacturing catalogues for cutting tools and inspection equipments”
3. P.Radhakrishnan , S.Subrmaniyum, V.Raju, “CAD\CAM\CIM”- New Age Interanational Pvt
Ltd
4. K.Hitomi , “ Manufacturing Systems Engg”, John Willey
5. Groover Mikell. P. “Fundamentals of modern manufacturing- materials, processes and systems
“2nd edition, Willey 2002.
 IP0174 FINANCIAL MANAGEMENT & COSTING
Objectives
 To learn and understand Materials Management Functions
 To learn and understand Financial Management Functions
Prerequisites
 Industrial Engineering and Management
 Production Planning and Control

Unit I
Financial Management (7)
Financial Function, Scope, goals and tools. Sources of finance.
Cost of Capital & Means of Finance

UNIT II
Ratio Analysis (7)
Classification, Ratio Analysis and its limitations.
Index Statement & Common Size Statement

UNIT III
Working Capital Management (7)
Concept and design of Working Capital, types of working capital, sources of working capital, Time
value of money, definition of cost and capital., Cash management, creditors management, debtors
management

Unit IV
Costing (2)
Methods of costing and elements of cost.
Material Cost (2)
Different methods of pricing of issue of materials.
Labour Cost (2)
Different methods, wages and incentive plans. Principles of good remunerating system, labour turnover.
Depreciation (1)
Concept, importance and different methods of depreciation

Unit V
Overheads (2)
Classification, collection of overheads, Primary and Secondary apportionment of overheads, absorption
of overheads- Machine hour and labour hour rate. Under and over absorption of overheads.

UNIT VI
Standard costing (1)
Concept, development and use of standard costing, variance analysis.
Marginal Costing (2)
Use of Marginal Costing in decision-making.
Capital Budgeting (2)
Control of Capital Expenditure, Evaluation Process-Payback approach, IRR, present value method.
Time: 7hrs per unit
Outcomes: At the end of the course student will be in a position to
 List down the factors that influence the application of the course content in the industrial
environment
  Undertake final year project work based upon the application of the course content
 Identify areas for research-oriented work based on the course content

Text Books:
1. N. K. Prasad, “Principles and Practice of Cost Accounting”, Book Syndicate Pvt. Ltd., Calcutta
700009.
2. B K Bhar, “Principles and Practice of Cost Accounting”, S Chand Pvt. Ltd., Calcutta 700009.
3. N. K. Prasad, “Financial Management”, Book Syndicate Pvt. Ltd., Calcutta 700009.
4.

Reference Books:
1. Colin Drury, “Management and Cost Accounting”, English Language Book Society, Chapman
and Hall London.
2. N K Prasad, Financial Management, Tata McGraw Hill, Pune
 IP0554 MANUFACTURING AUTOMATION AND CAM
Prerequisites (if any):

Objectives: 1. To make the students understand the concepts & broad principles of contents of the
course
11. Develop conceptual framework of the course
12. Aim is to provide insight of the subject
13. Sensitizes the students of the importance of course in real life environment

UNIT 1. Automation ,hydraulics and pneumatics

Automated manufacturing systems,levels of automationautomation principles and strategies,principles
of hydraulics and pneumatics,basic hydraulic circuits,hydraulic servo mechanism,proportional
valves,design of pneumatic circuits,hydroneumatic and electropneumatics,control in pneumatic systems.

UNIT 2.Hard and soft automation

SPMs, automats,Transfer lines,types,work part transfer mechanisms,control of production line,transfer
line performance,CNC machines,machining centers.

UNIT 3. Programmable automation.

Microprocessor,microprocessor instrumentation system for process control,logic gate and
control,PLC,computer process control,control system components,ADC/DAC conversion,linear
feedback control system,PID control

UNIT 4. Automatic material handling and inspection

.Automated guided vehicles systems,conveyor systems,analysis,carousel storage systems,automated
inspection,automatic gauging system

UNIT 5. Factory automation

Assembly systems,automated assembly,design for automated assembly,synchronous and non
synchronous material transfer,vibratory bowl feeders,hopper feeders,rotary disc
feeders,centrifugal,revolving feeders,industrial robots.

UNIT 6. Computer aided manufacturing,CIM and FMS.

DNC,cellular manufacturing,group technology,flexible manufacturing systems,computer control
systemFMS planning and implementation,Elements of CIM system

Outcomes: At the end of the course student will be in a position to

14. List down the factors that influence the application of the course content in the industrial
environment
15. Undertake final year project work based upon the application of the course content
16. Identify areas for research oriented work based on the course content
17. Apply the knowledge of the course in solving real life problems

TEXT BOOKS:
1.Automation,Production Systems and Computer Integrated Manufacturing-Mikell P Groover ,Pearson
Education Asia,2001
2.Pneumatic System-S.R.Majumdar,Tata McGraw Hill 2002 edition
REFERENCE BOOKS:
1.Mechanisation by pneumatic control-Werner Deport and Kurt Stool,Vol.1,2
2.Control Systems Engineering-Gopal,Willey Eastern Ltd
3.Hydraulics and Pneumatics –Andrew Parr
4.Microprocessor-Gaonkar,Penram International
 IP5544 PROCESS ENGINEERING & MFG AUTOMATION & CAM LAB
Prerequisites (if any):

Objectives: 1. To develop skills in the subject

2. Verify the principles of the course

Practical syllabus
Minimum 12 experiments from the following.
1. Process parameters and machining time determination of lathe and milling operations.
2. Process parameters and machining time determination of drilling, reaming & boring operations.
3. Process parameters and machining time determination of broaching, shaping and planning
operations.
4. Process parameters and machining time determination of grinding and finishing operations.
5. Process picture conventions and process sheet format .
6. Dimensional and tolerance analysis of part print.
7. General description and configuration of the part print.
8. Identification of locating , clamping, holding areas on work piece.
9. Process sheet design of one component for mass production by using general-purpose machines.
10. Process sheet design of one component CNC for batch production
11. Time estimation for assembly using flow charting techniques
12. Industrial visit to study process designing and its report
13. Construction of parametric solid model of any machine elements using software package.
14. Programming on CNC machine.
15. Programming on Robot application.
16. Flexible Manufacturing System.
17. Manufacturing resource planning.
18. Study of control valves, actuators, accumulators and pumps.
19. Study of hydraulic circuits: - hydraulic press, machine tools, automobile systems, etc
20. Performance analysis of positive displacement pumps.
21. Comparative studies on hydraulic circuit design for suitable industrial applications.

Outcomes: The student will

5. acquire the skills
6. improve ability to solve industrial problems on the subject
7. understand the technical writing of experiments.
8. have improved hands on skills
 9. be in a position to relate theory and practice

TEXT BOOKS:

4. D.F.Eary, G.E.Johnson” process engineering for manufacturing”; Prentice-Hall

5. P.W.Wang, J.Kelly” computer aided process planning
6. B. C Kuo, “Automatic control systems”, Prentice Hall India Pvt. Ltd., ISBN 0-87692-480-1.
7. Peter Rohner, “Industrial hydraulic control”

REFERENCE BOOKS:

6. H.W.Wage, “Manufacturing Engineering”, McGraw hill

7. “Manufacturing catalogues for cutting tools and inspection equipments”
8. P.Radhakrishnan , S.Subrmaniyum, V.Raju, “CAD\CAM\CIM”- New Age Interanational Pvt
Ltd
9. E. O Doebelin., “Measurement System, Application and Design”, Tata McGraw Hill
Publications Ltd., New Delhi, ISBN 0-07—17338-9.
10. W Bolton., “Mechatronics Electronic Control Systems in Mechanical and Electrical
Engineering”, Pearson Education (Singapore) Pvt Ltd., ISBN 81-7808-339-6.
 IP5564 PROJECT II

Objectives
 To undertake small project in group related to application of principles studied during the
course
Prerequisites

The student shall take up suitable project, the scope of the project shall be such as to complete it with the
time schedule, The term work shall consist of,
1. Fabrication of models, machines, prototypes based on new ideas, robots and machine based on hitech
systems and automation, experimental set-up, fabrication of testing equipment, renovation of machines,
etc. Above work shall be taken up individually or in groups. The group shall not be more than 4
students,
OR
Extensive analysis of some problems done with the help of a computer individually or in a group not
exceeding two students.
2. A detailed report on the work done shall include project specification, design procedure, drawings,
process sheets, assembly procedure and test results etc.

Project may be of the following types:

1. Manufacturing / Fabrication of a prototype machine' including selection, concept, design, material,
manufacturing the components, assembly of components, testing and performance evaluation.
2. Improvement of existing machine / equipment / process.
3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment, inspection gauges,
measuring instruments for machine tools.
4. Computer aided design, analysis of components such as stress analysis.
5. Problems related to Productivity improvements.
6. Problems related to value engineering.
7. Problems relating to material handling system.
8. Energy Audit of organization, Industrial evaluation of machine devices.
9. Design of a test rig for performance evaluation of machine devices.
10. Product design and development.
11. Analysis, evaluation and experimental verification of any engineering problem encountered.
12. Quality systems and management. Total Quality Management.
13. Quality improvements, In-process Inspection, Online gauging.
14. Low cost automation, Computer Aided Automation in Manufacturing.
15. Time and Motion study, Job evaluation.
16. Ergonomics and safety aspects under industrial environment
17. Management Information System.
18. Market Analysis in conjunction with Production Planning and Control.
OR
Computer based design / analysis or modeling / simulation of product(s), mechanism(s) or system (s)
and its validation or comparison with available benchmarks / results. When a group of students is doing
a project, names of all the students shall be included on every certified report copy. Two copies of
Project Report shall be submitted to the college. The students shall present their Project before the
examiners. The oral examination, shall be based on the term work submitted and jointly conducted by an
internal and an; external examiner from industry, at the end of second semester. Format of the project
report should be as follows:
1. Paper: The Project report should be types. printed on white paper of A-4 size.
2. Typing: The typing shall be with single spacing and on one side of the paper.
3. Binding: The Industrial Inplant Report should be submitted with front and back cover in black hand
bound, with golden embossing.
4. Margins: Left - 1.25", Right - 1". Top and Bottom 1 "
5. Sequence of Pages:
1. Title page
2. Certificate form Institute
3. Completion Certificate form Industry, if sponsored.
4. Acknowledgement
5. Abstract
6. Index
7. Nomenclature and Symbols
8. Actual Content
9. Conclusion
10. References.
6. Front cover: The front cover shall have the following details in block capitals
i. Title at the top.
ii. Name of the candidate in the centre, and
iii. Name of the Institute, Name of Industry, if sponsored and the year of submission on separate lines, at
the bottom.
7. Blank sheets: No blank sheets be left any where in the report. 8. Project Completion Certificate:
The approval sheet follow the title sheet and shall be as shown with proper spacing.

CERTIFICATE
This is to certify that Mr. /Ms
…………………………………………………
Has carried out a Project entitled, (Name)

…………………………………………during the course of his

(Name of Project)
training at………………………………………………..in
(Name of Industry)
partial fulfillment of the requirement of the B.E. Production Course of
University of Pune
at ……………………………during the academic Year ………………
(Name of Industry)

Date: (Guide)
Place:

(Examiner) (Head of Department)

 IP5574 SEMINAR-II

Objective: To learn about literature survey of the subject of his own interest

a) The objective of Seminar is to test the student on his/her ability for self-study and his/her ability to
communicate - Written and oral.

b) Seminar will be in the form of a report submitted by the student:

It will be -

1. Done by a student individually, on topic of his/her choice based on literature survey /a case
study wherever applicable / possible, and approved by the staff- in- charge,

2. A report with 15-20 pages of A-4 size paper, 1.5 spaced typed material, and appropriately
bound.

c) The Oral examination will be based on the report submitted and (orally) presented.

Outcome:
1. Improved presentations and communication skills
2. To understand the subject of his own interest
3. To understand the technical report writing
 IP0604 SURFACE ENGINEERING
Prerequisites (if any):

Objectives:
 To make the students understand the concepts & broad principles of contents of the course
 Develop conceptual framework of the course

1. Introduction of Surface dependent properties

Classification and scope of surface engineering in metals, ceramics, polymers and composites,
tailoring of surfaces of advanced materials. Surface protection (Physical);
Surface dependent engineering properties, viz., wear, friction, corrosion, fatigue, etc.; common
surface initiated engineering failures; mechanism of surface degradation; importance and necessity
of surface engineering

2 Various Surface Cleaning Processes

Classification & Selection of Cleaning processes. Acid & Alkaline, Salt bath , Ultrasonic ,
Mechanical cleaning, Pickling & descaling etc. Process details of each, applications of each
Environmental concern of each,

3 Surface modification techniques

classification, principles, methods, and technology used, conventional surface engineering methods:
Diffusion coatings like carburising, nitriding, cyaniding, hot dipping, galvanizing, anodizing
,Aluminising, Phosphetising etc.; Diamond & Diamond like Carbon thin films & coatings for
engineering surfaces .Electrochemistry and electro-deposition; electro less deposition .Scope and
application of conventionally deposited materials.; advantages and limitations of above mentioned
processes.

4. Other Surface engineering processes

Influence of manufacturing processes on various surface properties of an engineering component;
scope of surface engineering in augmentation of surface properties.
Other processes used in surface engineering – Thermal spray coatings, Physical vapour deposition,

Chemical vapour deposition.- Process, applications. mass production; surface engineering problems

related to substrate characteristics. Plasma enhanced Surface engineering, Ion Implantation .

5. Evaluation of engineered properties

control properties, response properties; surface geometry – characterization techniques (conventional
and recent trends); coating thickness measurements – laboratory techniques and special techniques
for accurate routine thickness measurements; adhesion measurement – conventional methods and
recent developments;

6. Recent trends in surface engineering

 Measurement of mechanical properties of engineered surface in nano scale; Evaluation of
tribological characteristics of engineered surface in macro, micro and nano scale, simulation of
actual application environment in tribometer. Use of Laser in Surface Engineering,

Time: 7 hrs per unit

Outcomes: At the end of the course student will be in a position to
 List down the factors that influence the application of the course content in the industrial
environment
 Undertake final year project work based upon the application of the course content

Text Books
1. Bharat Bhushan, Introduction to Tribology
2. N.J. Persson, Sliding Friction
Reference Books
1. Frank Philip Bowden, The Friction and Lubrication of Solids, Oxford Classic Texts
2. Gwidon Stachowiak, A W Batchelor, Engineering Tribology
3. ASM Hand Book , Vol. 5 , Surface Engineering.
4. K.G.Bundinski, M.K. Bundinski, Engineering Materials, Prentice Hall India, New Delhi.
5. Tool & Manufacturing Engineers Hand book, Vol.3, ‘ Materials Finishing & Coating’
 IP0614 PRODUCT DESIGN

Prerequisites (if any):

Objectives:
 To make the students understand the concepts & broad principles of contents of the course
 Develop conceptual framework of the course
 Aim is to provide insight of the subject

UNIT I :- Product methodology & the structure of Design Process , Introduction of Product
methodology , methodological problems, characteristics of methods, The phases of product design
process, foundations of phase models, three phase models etc

UNIT II:- Design materials & human factors in product design, material properties, metals, plastics,
rubber, woods & factors considered while designing for metals, plastics, rubber, woods etc,
Anthropometry factors, physiological factors, psychology factors, anatomy factors.

UNIT III :- Economic factors influencing design, product value, safety, reliability & environmental
considerations, economic analysis, break even analysis, profit & competitiveness, economic of a new
product design.

UNIT IV:- Value engineering in product design, introduction, historical perspective, nature &
measurement of value, importance of value, value analysis job plan, creativity, steps for solving & value
analysis, value analysis tests

UNIT V:- Strength considerations in product design, principal stress trajectories( force flow lines),
balanced design, criteria & objective of design, material toughness, resilience, designing for uniform
strength.

UNIT VI:- Modern APPROACHES TO PRODUCT DESIGN

Concurrent Design, Quality Function Development (QFD), Rapid Prototyping

Outcomes: At the end of the course student will be in a position to

 List down the factors that influence the application of the course content in the industrial
environment
 Identify areas for research-oriented work based on the course content
 Apply the knowledge of the course in solving real life problems
TEXT BOOKS:

1. Product design & Manufacturing- A.K.Chitale, R.C Gupta

2. Product Design : Fundamentals & Methods – N.F.M. Roozenburg & J.Eekels

REFERANCE BOOKS:

1. Product design & Manufacture- Jhon R Lindbeck

2. Mayall W.H., “Industrial Design for Engineers” London Liifee Books Ltd. 1967

3. Dale Huchingson R “New Horizons for Human Factors in Design ” McGraw Hill Company
19811.Indistrial Design-Mayall
 IP0194 OPTIMIZATION & SIMULATION
Prerequisites (if any):

Objectives:
 To make the students understand the concepts & broad principles of contents of the course
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

Unit I :- Advanced Linear programming

Duality, Economic interpretation of Dual, Solution of LPP using duality concept, Dual
simplex method. integer programming by branch & bound ,cutting plane method

Unit II:- Inventory Management

new product planning, inventory system, different Inventory models, problems on inventory model.

Unit III :- Dynamic programming

Introduction, application, capital budgeting, different problems solved by Dynamic programming

Unit IV :- Queuing theory

Operating characteristics, Poisson single and multi channel queuing system models.

Unit V :- Geometric and Goal Programming.

Definition, Introduction, application of Geometric and Goal Programming

Unit VI:- Simulation definition, Introduction, application, Monte Carlo simulation

Outcomes: At the end of the course student will be in a position to

 List down the factors that influence the application of the course content in the industrial
environment
 Undertake final year project work based upon the application of the course content
 Identify areas for research-oriented work based on the course content

TEXT BOOKS:
1. S. D. Sharma, “Operations Research”, Kedarnath Ramnath and company Publications.
2. P. K. Gupta, D. S. Hira, “Operations Research”, S Chand and Co. Ltd., ISBN 81-219-0281-9.
REFERENCE BOOKS:
1. F. S. Hillier, G. J Lieberman, “Introduction to Operations Research”, Tata McGraw-Hill,
ISBN 0-07-047387-0.
2. H. M. Wagner, “Principles of Operations Research”, Prentice-Hall India, ISBN 81-203-0162-
5.
3. A. Ravindran, “Operations Research”, Tata McGraw-Hill.
4. S. K. Basu, D. K. Pal, H. Bagchi, “Operations Research for Engineers”, Oxford and IBH
Publishing Co. Pvt. Ltd., ISBN 81-204-1251-6.
5. R. Panneerselvam, “Operations Research”, Prentice Hall of India Ltd., ISBN 81-203-
1923-0.
6. H. A Taha., “Operations Research”, An introduction Prentice Hall Pvt. Ltd., ISBN 81-203-
1222-8.
 IP0074 WORLD CLASS MANUFACTURING

Prerequisites (if any):

Objectives:
 Develop conceptual framework of the course
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

Course Contents

UNIT 1:Models of world class manufacturing

 Hall’s framework of value –added engineering
 Schonberger,s framework of world class manufacturing
 Various models of world class manufacturing
 JIPM TPM Award, EFQM Award, RBNQA Award
UNIT 2: Lean Manufacturing & Services
 Lean Mfg tools
 Value Stream Mapping
 Implementation Roadmap.
UNIT 3: Material processing and handling tools :
 Set-up Time Reduction: SMED Methodology for Set-up reduction, Set-up
Reduction Projects.
 Design of JIT: Flexible Manufacturing Systems (FMS), Concurrent Engineering,
Design for Manufacturability and Assembly (DFMA), Collaborative Product Commerce
(CPC)
 Group Technology, Focused Factories and Cellular Manufacturing: Work cell
concepts and applications, Work cell design, work cell staffing and equipment issues
UNIT 4: Total Productive Maintenance:
 Outline of TPM
 Production Efficiency
 Improvement program for Zero failures
 Implementation of Jishu-Hozen activities
 Planned Maintenance
 Initial-Phase Management
 Quality Maintenance
 Operation & Maintenance skill Development
 Implementation of TPM in the Administrative & Indirect Departments
 Zero Accidents & Zero Pollution
 Small-Group activities of TPM
UNIT 5: Business Process Reengineering
  BPR Concepts, Practices & Philosophy.
 Key features and guiding principles of Reengineering,
 Kinds of changes that occur in reengineering,
 Changes required on Behavioral Side in a BPR Project
 Concepts of Business and Core Processes in BPR.
 Different Management Audit to initiate BPR Projects.
 Critical Analysis of Business Processes through Strategic Relevance Grid and Critical
Success Factors Method considering Core and Supporting Processes.
 Formulating Future desired. State of Business by Understanding Relationship between
Vision, Mission, Policies and Goals of Organization.
UNIT 6: World Class services in Banking, Financial services, IT, ITES, Logistics, Retail, Hospitals,
Travel & Tourism, Power sector, Public utilities. (Guest Lectures, Internet research, Library, etc.)

Time: 7hrs per unit

Outcomes: At the end of the course student will be in a position to
 List down the factors that influence the application of the course content in the industrial
environment
 Identify areas for research-oriented work based on the course content
 Apply the knowledge of the course in solving real life problems

Text book:
1. World Class Manufacturing -A strategic perspective by B.S. Sahay, Saxena, Macmillan,
India
2. Hammer M. and Champy J. Re-engineering the corporation - Harper Collins.
Reference Books:
1. Cause and Effect Lean – The essentials of Lean Manufacturing by John Bicheno
2. Maintainability Engineering – Blanchard & Verma
3. World Class Manufacturing- Case Book-R J Schonberger (Free press)
4. World Class Manufacturing – Richard Schonberger
5. Introduction to TPM: Total Productive Maintenance by Nakajima Seiichi
6. Total Productive Maintenance by Terry Wireman (Industrial Press)
7. Management Of Industrial Maintenance By A. Kelley, M.J. Harris (Newness
Butterworths)
8. Complete Handbook of Maintenance Management By J.E. Heintzelman (Prentice Hall)
9. TPM material/ books published by JIPM (Japanese Institute of Plant Maintenance)
Lean Thinking by James Womack & Daniel Jones
 IP0214 SUPPLY CHAIN MANAGEMENT

Prerequisites (if any):

Objectives:
 Aim is to provide insight of the subject
 Sensitizes the students of the importance of course in real life environment

UNIT 1 Concept of SCM

- Concept of Logistics Mgmt, Supply Chain, Types of Supply Chain
- Functions in SCM, Transportation Mgmt, Warehousing Mgmt
- Warehouse Management Systems
UNIT 2 Designing the Supply Chain Network
- Designing the Distribution Network
- Network Design
- Network Design in an Uncertain Environment
UNIT 3 Planning Demand & Supply in a Supply Chain
- Demand Forecasting
- Aggregate Planning
- Planning Supply & Demand
UNIT 4 Planning & Managing Inventories in a Supply Chain
- Managing Economies of scale: Cycle Inventory
- Managing Uncertainty: Safety Inventory
- Optimal Level of Product Availability
UNIT 5 Sourcing, Transporting & Pricing products
- Sourcing Decisions
- Transportation
- Pricing & Revenue Management
UNIT 6 Co-ordination & Technology in the Supply Chains
- Co-ordination in Supply Chain
- Information Technology and Supply Chain
- E-business & Supply Chain

Time: 7 hrs per unit

Outcomes: At the end of the course student will be in a position to
 Undertake final year project work based upon the application of the course content
 Identify areas for research oriented work based on the course content
 Apply the knowledge of the course in solving real life problems

Text Books
1. Purchasing & Supply Management - Dobler and Burt
2. Strategic Logistics Management – Lambert
Reference Books
1. Logistical Management - The Integrated Supply Chain Process – Bowersox
2. Materials & Logistics Management - L.C.Jhamb
3. Logistics & Supply Chain Management – Christopher
4. Supply Chain Management - Sunil Chopra
5. Logistics & Supply Chain Management – Raghuram